Complexity is a cost driver in manufacturing processes. Manufacturers have turned to additive manufacturing to simplify the production of complex objects. The flange wheel presented additional challenges due to its design complexity and the goal of replacing metal with a carbon-filled PEEK, a difficult thermoplastic to prototype. In the manufacturing of PEEK parts, process parameters need to be tightly controlled to achieve target performance, and Liebherr worked with Aitiip to develop and verify a manufacturing process that would meet the following requirements: - High-speed manufacturing process that will lead to 30% cost reductions - Recyclable materials - Light-weighting – with a goal of reaching a 40% weight reduction - One-shot manufacturing